Pattern Glass Resin Filling and Laser Curing for Flexible Displays
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Solution Overview
Problem
The manufacturing process of pattern glass for flexible displays is inefficient in filling and curing resin in pattern areas, leading to reduced reliability.
Innovation Solution
A method involving the use of guide films, support films, and a shielding film with a through-hole to inject and cure resin in pattern areas of the glass using a laser beam, enhancing the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin is injected into pattern area without guide films and shielding films, then manufacturing process is simpler, but resin filling and curing reliability is reduced
Solution Approach 1:
The patent divides the manufacturing process into multiple stages using separate guide films and shielding films. Guide films are used to define the injection path and pattern area boundaries, while shielding films are used to control laser beam irradiation areas. This segmentation allows each film to perform a specific function, improving reliability without requiring a single complex multi-functional structure.
Solution Approach 2:
The guide films and shielding films are applied to the pattern glass before resin injection and laser curing. The guide films are positioned to define the injection channels and pattern areas in advance, and the shielding films are positioned to pre-define which areas will receive laser irradiation. This preliminary preparation ensures that the resin filling and curing processes proceed reliably without requiring complex real-time control.
2Reliability
If multiple guide films and shielding films are used, then resin filling and curing reliability is improved, but manufacturing process becomes more complex
Solution Approach 1:
The patent uses thin film structures (guide films and shielding films) that can be easily applied to the pattern glass surface. These thin films are flexible and can be positioned precisely without requiring complex handling procedures. The films serve as temporary guides and shields during manufacturing, then can be removed after the resin curing process is complete.
Solution Approach 2:
The guide films and shielding films act as intermediary elements between the resin injection system and the pattern glass, and between the laser beam and the pattern glass. These intermediary films simplify the overall system by providing physical guides and shields that eliminate the need for complex alignment mechanisms and control systems.
3Productivity
If laser beam is irradiated to cure resin, then curing efficiency is improved, but harmful effects on surrounding areas increase
Solution Approach 1:
The shielding films are used to extract or block the laser beam from reaching areas that should not be cured. The films are positioned to allow laser irradiation only through specific openings or areas where resin needs to be cured, while blocking the beam from reaching other areas of the pattern glass. This selective blocking prevents harmful thermal and optical effects from spreading to unintended areas.
Solution Approach 2:
The shielding films create local variations in laser beam transmission across the pattern glass surface. Areas with openings in the shielding films receive laser irradiation and undergo curing, while areas without openings block the laser beam and remain uncured. This local differentiation allows high curing efficiency in the target areas while preventing harmful effects from affecting the entire pattern glass uniformly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves the reliability of pattern glass manufacturing by ensuring effective resin filling and curing, thereby enhancing the mechanical properties and performance of flexible displays.
Implementation Method 1
curing the uncured resin filled in the pattern area by irradiating a laser beam toward the pattern area exposed through the through-hole
Data Source
AI summary
A method for manufacturing a pattern glass includes: providing a plurality of guide films on a pattern glass including flat areas and a pattern area between the flat areas, wherein the guide films are in contact with side surfaces of the flat areas; providing a first support film on top surfaces of the pattern glass and the guide films; providing a second support film on bottom surfaces of the pattern glass and the guide films; providing a shielding film having a through-hole formed therein on at least one selected from among the first and second support films, wherein the through-hole overlaps with the pattern area; injecting an uncured resin into the pattern area of the pattern glass through an injection channel formed between the guide films; and curing the uncured resin filled in the pattern area by irradiating a laser beam toward the pattern area exposed through the through-hole.